DELL CONFIDENTIAL 1

Dell Manufacturing & .NET

FOR INTERNAL AND EXTERNAL USE

Kim HammondsOctober, 2007

DELL CONFIDENTIAL 2

Agenda

• Dell Portfolio and Supply Chain

• Dell’s Global Presence

• Managing the Dell IT Environment

• Factory and Supply Chain Processes

• Toolset to Manage Development Process

• Architecture

• Real Time Tracking & Visibility

• Flashboard

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Dell Product Portfolio PowerEdge ServersPowerVault StoragePowerApp Server Appliances

OptiPlex Desktops XPS Notebooks

XPS Desktops

Precision Workstations

Latitude Notebooks Software &

AccessoriesVOSTRO

Suppliers CustomersDELL

The Direct Model

• Continuity of Supply

• E-Business Collaboration

• Low-Cost Manufacturers

• Technology Leaders

• Best Customer Experience

• Highest Quality• Low Cost

Efficiency • Partnering/

Virtual Integration

• Product Quality and Reliability

• Service and Support

• Price for Performance

• Customization • Latest

TechnologyDell Confidential

Dell Supply Chain

Supply Chain & Factory Planning

• Dell facilities act as manufacturing centers, not warehouses – only inventory needed for next 2 hours of orders is on site

• Provides direct signal of Dell customer demand for suppliers• Dell’s performance to customer orders is directly linked to our suppliers’

level of support

SLCDell

Manufacturing

Buy-to-Plan Build-to-OrderS

uppl

iers

Material requested to build customer orders

Materials delivered in time to meet up with customer order

“push” “pull”

Dell Confidential

Where We Are Today

Contact Center (41)Manufacturing (9) Fulfillment (6)

• Revenue of $57.4B last four quarters

• #25 on the Fortune 500

• Fortune “Most Admired” Top 10 – 1999, 2000, 2001, 2003, 2004, 2006 and #1 in 2005

• CIO 100 – 10 of last 13 years, including 2000, 2002, 2003, 2004, 2006, 2007

• InformationWeek 500 Top 50 – 2006

• Dell IT in more than 34 countries

Dell Confidential

Managing a Global Environment Hardware

~ 110,000+ client systems ~ 20,000+ Dell servers 18,000 Mobile Devices

Networks 107 Dell global WAN sites 39 locations 307 WAN links 420 metro Dell-managed fiber

paths 855 wireless access points 177 dedicated extranet partner

links

Total SAN Storage 5.8+ Petabytes Second-largest storage area

network in US, Top 5 globally.*

* Source: Brocade Communications Systems Inc.Dell Confidential

IT By the Numbers: We Are the Scalable Enterprise

Data and Networks:– What is the total size of the Dell Data Warehouse?

330 Terabytes on 84 nodesAnd we run 16,000 reports each day

– How many emails do our servers handle each day?1.8 million outbound40 million inbound (94% of these are spam!)

– How many voice calls do we handle each month?16.5 million inbound toll-free calls3 million outbound calls

– How many suspicious data packets do our firewalls reject each day?About 400 million per day (or 4,000 suspicious data packets every second!)

Dell Confidential

IT By the Numbers: We Are the Scalable Enterprise

Dell.com:– How many Dell.com page requests last quarter?

3.8 billion

– How many systems are configured each week on Dell.com?~1 million — and 1 million per day in peak holiday season

– How many visits to Dell.com last quarter?400 million

– How many unique visitors to Dell.com last quarter?133 million

– What is the highest number of pages ever requested in one minute?64,584 (and we handle all that traffic on only 28 Dell PE6650 servers!)

Dell Confidential

IT By the Numbers: We Are the Scalable Enterprise

Complexity:– How many Contact Centers, Manufacturing, & Distribution sites?

41 contact centers, 15 manufacturing/distribution

– How many changes in the environment do we handle each year?About 15,000

– In how many countries, languages & currencies does Dell do business?81 countries, 24 languages, and 26 currencies

– How much cabling is needed for a typical factory?166 miles of cabling & 10,000 LAN drops in a typical factory

– How may security patches do we implement per year? 7.5 Million security patches/year

– How many systems are running on our network?– 20,000 Servers– 110,000 Clients– 18,000 Mobile Devices

Dell Confidential

DELL CONFIDENTIAL 11

Show Dell / Microsoft Video

Factory ProcessSupply Chain - Dell’s World Class Supply Chain Allows for Just in Time Inventory

Factory Planning - Orders Organized and Prioritized by Factory – in 2 hour blocks.

Kitting - Parts are picked and placed on the tote, alongside the chassis.

Build - Computer is put together with all the parts from the tote added to the chassis.

Burn - Operating System and other customer selected software is ‘burned’ onto the hard drive. Extended Test is also performed.

Boxing - Computer is placed in a box, and remaining materials such as documentation, keyboard and mouse are placed inside box.

Shipping / Distribution - Box receives shipping label and is routed via shipping and distribution system directly to the back of the truck.

Dell Confidential

Factory Automation Demo

CIMPLICITY Server

Controller BGLJ961

P2M Display

Sta

tion

Physical Wiring

Basic Process Flow

6.Release5. Go4.Done3. Stop2. To P2M1.Trigger

Message

AC

F_R

EA

D

AC

F_W

RIT

E

DONE

P2M Server P2M

Display Picks

Stop

Done

Go

AC

F_W

RIT

E

.NE

T S

oftw

are

Developing the I/T SystemsKey Tenants for Development & Testing

• Source Control

• Check-In Policies (i.e. Testing)

• Custom Policies (i.e. Code Review)

• Work Items (i.e. Tasks, Defects)

• Reporting (Canned Reports)

• BVT (Automated Build, Test, Deployment)

• Code Coverage Analysis

• Continuous Integration Testing

• Performance & Load Testing

EnvisioningResource Planning& Chartering

Planning Developing Stabilizing

Horizon Process

Integration Architecture

Devices (Scanners, RFID, Printers)

Program Logic Controller (PLC)

OPC Server

OPC Client

CIMPLICITY

Tracker

Integration Services Microsoft .NET 3.0 and Windows Communications Framework

Production

Reporting ServiceBlackberry

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cto

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Vis

ual

izat

ion

Screens / LCD Web View

Reporting

Dell IT

IT S

yste

ms

OPC Server

OPC ClientInte

gra

tio

n

Factory Automation

Integration Architecture

Devices (Scanners, RFID, Printers)

Program Logic Controller (PLC)

OPC Server

OPC Client

CIMPLICITY

Tracker

Integration Services Microsoft .NET 3.0 and Windows Communications Framework

Production

Reporting ServiceBlackberry

Eq

uip

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Screens / LCD Web View

Reporting

Dell IT

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OPC Server

OPC ClientInte

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Factory Automation

Technology Running Dell’s Manufacturing Integration Layer

• Visual Studio 2005

• Visual Studio Team System

• NET 3.0 WCF

• Enterprise Library 3.0

• Windows 2003 & IIS 6.0

• Site Info.NET (Custom to Dell)

• SQL Server 2005

• MOM

Enterprise Library 3.0

Caching

Security

Data Access

Logging

ExceptionHandling

Plug-inConfigHelpers & Design

Instrumen-tation

ObjectBuilder

Cryptography

Core

Policy Injection

Validation

• Data Access – provides and easy transparent way to connect to databases• Logging – standard way to log information that is critical to run Dell’s business • Exception Handling – gives Dell developers a standard way to handle exceptions• Security – caches authentication data

Dell Uses the Enterprise Library for Standardization and Re-Useable Components

SiteInfo.NET

• Centrally stored applications settings• Ability to remotely manage changes to several application servers at once• Encryption of connection strings or sensitive data• Role based security for administration• Auditing of settings changes• Client access to settings restricted by host• Environment and region layers to differentiate settings

Dell’s Internal Solution to Handle “Configuration Settings Management” for .NET applications

Easily Manage Multiple Configuration Files

Technology: ASP.NET UI and SQL Server 2005 Backend

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Real Time Tracking & Visibility

Devices (Scanners, RFID, Printers)

Program Logic Controller (PLC)

OPC Server

OPC Client

CIMPLICITY

Tracker

Integration Services Microsoft .NET 3.0 and Windows Communications Framework

Production

Reporting ServiceBlackberry

Eq

uip

men

tP

roce

ssC

on

tro

lS

CA

DA

Bu

sin

ess

Lo

gic

Fac

tory

V

isu

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Screens / LCD Web View

Reporting

Dell IT

IT S

yste

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OPC Server

OPC ClientInte

gra

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Factory Automation

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Replay Events and System Flow

Real Time Tracking & Visibility

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Metrics• Turns the logged data into useful information in the form of reports for

engineers, production staff, maintenance and management.• First implementation of the industry standard S-95 model which consist of a

plant model and standard relational database tables models. • First implementation of providing industry standard OEE for measuring

equipment effectiveness. • Application is plug and play in all factories with minimal configuration

changes.

Capabilities

• Hourly Reports

• Track Code Genealogy

• Block Starved

• WIP

• Cycle Time

• OOE & Equipment

• Scanners

• MTBF

• Ad-Hoc Reporting

• Much More …

FlashBoard

Technology

• NET 3.0 WCF

• ASP.NET

• Windows 2003

• IIS 6.0

• SQL Server 2005

• MOM

Description

Flashboard (Factory Logging And Services Health Dash Board), displays real time data to assist in troubleshooting the Cimplicity Integrated Services Layer.

Information Provided

• Average IIS Round Trip

• Average IT Call Round Trip

• Errors In a ROW

• Last IT Call with Errors

• Last Good IT Call

• Successful IT Calls (1 hour)

• Bad IT Calls (1 hour)

• Total IT Calls (1 hour

• Server IT Call Utilization

FlashBoard

DELL CONFIDENTIAL 24

Back Up

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Real Time Tracking & Visibility

Real Time Locator

ION Case Study

The Microsoft and Dell teams worked together to create load harnesses for each application.Determine the realistic Load for an application.

Multiply that load by at least 10x (in most cases more)

• Load TestUtilize CLR Profiler to gather metrics on memory allocation/release under

load.Increase the load approximately 10 fold and run again (3 cycles)

• Performance TestUtilize Windows Performance Monitor to gather counter metrics under

load.Increase the load approximately 10 fold and run again (3 cycles)

The Microsoft Team collected over 7 Gig of metric data during this process.

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Factory Layout

KittingBuildBurnBoxing Ship

Factory Process

MANUFACTURING SYSTEMS

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DOMS

OFS

WIPS

PLC

Printers

Scanners

Lifts/ Tapers

Conveyors

Other..

Laser Etcher, etc

Kitting

Build

Burn

Boxing

Shipping

Order Induction

FACTORY HARDWARE

Lifts/ Tapers

CIMPLICITY

P2M

GPCS

IBMS

ION

MIAS

ADS

Devices (Scanners, RFID, Printers)

Program Logic Controller (PLC)

OPC Server

OPC Client

CIMPLICITY

Tracker

Integration Services Microsoft .NET 3.0 and Windows Communications Framework

Production

Reporting ServiceBlackberry

Eq

uip

me

nt

Pro

ce

ssC

on

tro

lS

CA

DA

Bu

sin

es

sL

og

icF

act

ory

V

isu

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Screens / LCD Web View

Reporting

Dell IT

IT S

yste

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OPC Server

OPC ClientInte

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Factory Automation

Global View

Real Time Tracking & Visibility